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Abstract:

A device for forming headrest in a foaming die, which includes a lid
engagement mechanism operable to keep a lid member engaged in an
injection nozzle placed in the foaming die, thereby preventing leakage of
liquid foaming agent from the injection nozzle. Further, the device
includes a lid disengagement mechanism operable to disengage the lid
member from the injection nozzle and an injection gun movable vertically.
The lid disengagement mechanism includes a pressure element provided at
the injection gun. Upon downward movement of the injection gun, the
pressure element acts on the lid member, so that the lid member is
disengaged from the injection nozzle and the injection gun is then
engaged with the injection nozzle, thereby allowing liquid foaming agent
to be injected into a trim cover assembly placed in the foaming die.

Claims:

1 A device for forming a headrest, comprising:a foaming die element
including:a cavity formed in the foaming die element, said cavity
allowing a three-dimensional trim cover assembly to be placed therein,
wherein said three-dimensional trim cover assembly is preformed in a
shape substantially conforming to a resultant headrest; anda through-hole
formed in the foaming die element so as to communicate said cavity with
an outside of said foaming die element, said through-hole having outward
opening defined in said outer side of said foaming die element and being
adapted for allowing an injection nozzle to be placed therein, such that
one opened end portion of said injection nozzle extends into an inside of
said three-dimensional trim cover assembly placed in said cavity, while
another opened end portion of the injection nozzle is disposed at said
outward opening of said through-hole;a lid engagement mechanism
including:a plate member pivotally connected with said foaming die
element, said plate member having one end portion and another end portion
opposite to said one end portion;a lid member fixed on said one end
portion of said plate member, said lid member being adapted to be engaged
in and closely fitted in said another opened end portion of the injection
nozzle; anda biasing element for biasingly causing said one end portion
of said plate member to rotate towards said outward opening of said
through-hole to thereby engage and fit said lid member in said another
opened end portion of said injection nozzle placed in said
through-hole;an injection molding unit having an injection mechanism and
an injection gun, said injection molding unit being operable to supply a
liquid foaming agent and discharge the liquid foaming agent outwardly
from said injection gun via said injection mechanism, wherein said
injection mechanism and said injection gun are movable vertically; anda
lid disengagement mechanism including a pressure element arranged at said
injection mechanism so as to be disposed near to said injection gun and
extend vertically therefrom, wherein said pressure element is adapted to
press said another end portion of said plate member associated with said
lid closing mechanism against a biasing force of said biasing element in
order to disengage said lid member from said another opened end portion
of said injection nozzle placed in said through-hole,wherein, said lid
member is normally biased to fit engagement in said another opened end
portion of said injection nozzle placed in said through-hole, thereby
temporarily retaining said particular another opened end portion in
closed and sealed state, and wherein, upon movement of said injection
mechanism towards said foaming die element, said pressure element is
simultaneously moved toward and press said another end portion of said
plate member to cause disengagement of said lid member from said another
opened end portion of said injection nozzle, thereby opening and exposing
said particular another opened end portion, and then, said injection gun
is engaged in the thus-exposed another opened end portion of the
injection nozzle to thereby allow said liquid foaming agent to be
injected through said injection gun and said injection nozzle into the
inside of said there-dimensional trim cover assembly placed in said
foaming die element.

2. The device as claimed in claim 1, which further includes an injection
gun cleaning mechanism comprising: an operative hollow body; a cleaning
brush rotatably supported in said operative hollow body; and a drive
means for causing said operative hollow body and said cleaning bush to
move toward and away from said injection mechanism and also causing
rotation of said cleaning brush, wherein, upon operation of said drive
means, said operative hollow body is moved to said injection mechanism,
so that said cleaning brush is brought to contact with an edge of said
injection gun and rotated to clean off a residual portion of said liquid
foaming agent attached to said edge.

3. The device as claimed in claim 1, which further includes:an injection
gun cleaning mechanism comprising: an operative hollow body; a cleaning
brush rotatably supported in said operative hollow body; and a drive
means for causing said operative hollow body and said cleaning brush to
move toward and away from said injection mechanism and also causing
rotation of said cleaning brush, wherein, upon operation of said drive
means, said operative hollow body is moved to said injection mechanism,
so that said cleaning brush is brought to contact with an edge of said
injection gun and rotated to clean off a residual portion of said liquid
foaming agent attached to said edge;wherein said operative hollow body
includes at least two different sloped wall regions defined in a side
thereof facing toward said injection mechanism and said injection gun,
andwherein said pressure element comprises: a stationary pressure element
fixed to said injection mechanism; and a movable pressure element
pivotally connected with said stationary pressure element at a pivotal
point, said movable pressure element having at least one roller rotatably
provided therewith,with such an arrangement that, when said operative
hollow body is moved toward said injection mechanism, said at least one
roller is contacted with and rotated on said at least two different
sloped wall regions of said operative hollow body as well as said
cleaning brush, while simultaneously said movable pressure element is
thereby pivotally moved about said pivotal point and inclined relative to
said stationary pressure element so as to ride over said operative hollow
body, thereby preventing both said upper and movable pressure elements
from interference with said operative hollow body in motion.

Description:

BACKGROUND OF THE INVENTION

[0001]1. Field of the Invention

[0002]The present invention relates to a device for forming a headrest. In
particular, the invention is directed to a device for automatically
forming a headrest, which is provided with a foaming die and designed to
automatically inject a liquid foaming agent into a trim cover assembly
placed in the foaming die and cure the liquid foaming agent into an
increased mass of foam padding integrally filled in the trim cover
assembly, thereby producing a resultant headrest.

[0003]2. Description of Prior Art

[0004]In general, a conventional foaming process for forming a headrest by
means of a foaming die unit requires the steps of: providing a preformed
three-dimensional trim cover assembly of a configuration conforming to a
contour of headrest, with a headrest stay attached thereto; placing such
trim cover assembly with the headrest stay in the foaming die; then
inserting an injection nozzle into the trim cover assembly; injecting a
liquid foaming agent via that injection nozzle into the inside of the
trim cover assembly; and curing the liquid foaming agent into an
increased mass of foam padding filled in the trim cover assembly together
with the headrest stay in an integral manner.

[0005]The aforementioned foaming process has been with the problem that
the increasing mass of foam padding or foamed material is forced into the
injection nozzle during the foaming operation and eventually discharged
form that injection nozzle to the outside of the die.

[0006]Hitherto, in order to prevent such undesired discharge of foamed
material, the foaming die unit is provided with a movable lid for closing
the hole of the injection nozzle, and such lid must be manually retained
by a worker in a state pressed against the injection nozzle to keep
closing the hole of injection nozzle, as for example disclosed from the
Japanese Patent No. 3650860.

[0007]In other words, it has been required on the worker's side to keep
pressing the lid against the hole of injection nozzle for a predetermined
period of time until the liquid foaming agent is cured into a final mass
of foam padding in the trim cover assembly.

[0008]But, in mass production of headrest, during the time for curing the
liquid foaming agent, another foaming die containing a trim cover
assembly and headrest stay therein is transferred to the worker for the
above-described liquid foaming agent injection operation, and therefore,
the worker must stop such another foaming die until the liquid foaming
agent is cured in the first foaming die, while the worker has to be ready
to inert an injection gun to the hole of the injection nozzle provided on
that another foaming die. Thus, the conventional headrest production
system of this kind takes much time at the steps where the worker keeps
closing the hole of the injection nozzle and thereafter inserts an
injection gun to an injection nozzle of next foaming die.

SUMMARY OF THE INVENTION

[0009]In view of the above-stated drawbacks, it is a purpose of the
present invention to provide a device for forming headrest which is
operable to automatically close and open an opened end portion of
injection nozzle and automatically inject a liquid foaming agent via the
injection nozzle into a trim cover assembly placed in a foaming die and
cure the liquid foaming agent therein, while automatically maintaining
the opened end portion of injection nozzle in a closed state to prevent
leakage of the liquid foaming agent therethrough.

[0010]In order to achieve such purpose, in accordance with the present
invention, a device for forming a headrest is basically comprised of.
[0011]a foaming die element including: [0012]a cavity formed in the
foaming die element, said cavity allowing a three-dimensional trim cover
assembly to be placed therein, wherein the three-dimensional trim cover
assembly is preformed in a shape substantially conforming to a resultant
headrest; and [0013]a through-hole formed in the foaming die element so
as to communicate said cavity with an outside of the foaming die element,
the through-hole having outward opening defined in the outer side of the
foaming die element and being adapted for allowing an injection nozzle to
be placed therein, such that one opened end portion of the injection
nozzle extends into an inside of the three-dimensional trim cover
assembly placed in the cavity, while another opened end portion of the
injection nozzle is disposed at the outward opening of the through-hole;
[0014]a lid engagement mechanism including: [0015]a plate member
pivotally connected with the foaming die element, the plate member having
one end portion and another end portion opposite to the afore-said one
end portion; [0016]a lid member fixed on afore-said one end portion of
plate member, the lid member being adapted to be closely engaged in the
afore-said another opened end portion of the injection nozzle; and
[0017]a biasing element for biasingly causing the afore-said one end
portion of the plate member to rotate towards the outward opening of the
through-hole to thereby engage and fit the lid member in the afore-said
another opened end portion of the injection nozzle placed in the
through-hole; [0018]an injection molding unit having an injection
mechanism and an injection gun, the injection molding unit being operable
to supply a liquid foaming agent and discharge the liquid foaming agent
outwardly from the injection gun Via the injection mechanism, wherein
said injection mechanism and said injection gun are movable vertically;
and [0019]a lid disengagement mechanism including a pressure element
arranged at the injection mechanism so as to be disposed near to the
injection gun and extend vertically therefrom, wherein the pressure
element is adapted to press afore-said another end portion of the plate
member associated with the lid closing mechanism against a biasing force
of the biasing element in order to disengage the lid member from the
afore-said another opened end portion of the injection nozzle placed in
the through-hole,

[0020]wherein, the lid member is normally biased to engagement in the
afore-said another opened end portion of the injection nozzle placed in
the through-hole, thereby temporarily retaining the afore-said particular
another opened end portion in closed and sealed state, and wherein, upon
movement of the injection mechanism towards the foaming die element, the
pressure element is simultaneously moved toward and press the afore-said
another end portion of plate member to cause disengagement of the lid
member from the afore-said another opened end portion of injection
nozzle, thereby exposing that particular another opened end portion, and
then, the injection gun is engaged in the thus-exposed another opened end
portion of the injection nozzle to thereby allow the liquid foaming agent
to be injected through the injection gun and injection nozzle into the
inside of the there-dimensional trim cover assembly placed in the foaming
die element.

[0021]As one aspect of the present invention, an injection gun cleaning
mechanism may be provided in the above-described device, which comprises:
an operative hollow body; a cleaning brush rotatably supported in the
operative hollow body; and a drive means for causing the operative hollow
body and the cleaning bush to move toward and away from the injection
mechanism and also causing rotation of the cleaning brush, wherein, upon
operation of the drive means, the operative hollow body is moved to the
injection mechanism, so that the cleaning brush is brought to contact
with an edge of the injection gun and rotated to clean off a residual
portion of the liquid foaming agent attached to the edge.

[0022]As another aspect of the invention, the afore-said operative hollow
body may include at least two different sloped wall regions defined in a
side thereof facing toward the injection mechanism and injection gun, and
the afore-said pressure element may comprise: a stationary pressure
element fixed to the injection mechanism; and a movable pressure element
pivotally connected with said stationary pressure element, said movable
pressure element having at least one roller rotatably provided therewith.

[0023]Other various features of the present invention will become apparent
from reading of the description, hereinafter, with reference to the
accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is a diagram illustrating a whole of device for forming
headrest in accordance with the present invention;

[0025]FIG. 2 is a partly broken and partly sectioned plan view showing a
principal part of the device for forming headrest;

[0026]FIG. 3 is a partly broken and partly sectioned plan view for
explanatorily showing the state where a lid disengagement mechanism is
operated to open an injection nozzle and a liquid foaming agent is
injected via such injection nozzle into a trim cover assembly;

[0027]FIG. 4 is a partly broken and partly sectioned plan view for
explanatorily showing the state where a lid engagement mechanism is
operated to close the injection nozzle, while injection mechanism and
injection gun are moved upwardly;

[0028]FIG. 5 is a partly broken and partly sectioned plan view showing a
principal part of an injection gun cleaning mechanism;

[0029]FIG. 6 is a partly broken schematic perspective view showing a
foaming die to be used in the device and a basic headrest unit to be
placed in the foaming die; and

[0030]FIG. 7 is a partly broken schematic perspective view of a resultant
headrest produced by the device.

DETAILED DESCRIPTION OF PREFERRED

Embodiment of the Invention

[0031]Referring to FIGS. 1 to 6, there is illustrated a preferred
embodiment of device for forming a headrest, as generally designated by
(HD), in accordance with the present invention.

[0032]The device (HD) is designed to automatically effect required
operations for foaming operations in order to form a resultant headrest
(HR) shown in FIG. 7. Briefly stated, this device (HD) is operable to
inject a liquid foaming agent (B') into the inside of three-dimensional
trim cover assembly (A) preformed in a shape substantially conforming to
the headrest, the trim cover assembly (A) being placed in a foaming die
unit provided as one of elements of the device (HD) (the foaming die unit
is shown by each of designations 1(A), 1(B) and 1(C) for example), and
thereafter cure the liquid foaming agent (B') into an increased mass of
foam padding (B) in that trim cover assembly (A).

[0033]At first, as shown in FIG. 6, a basic headrest unit (HR') is
provided, which is to undergo a foaming processes by operation of the
device (HD) into a resultant headrest (HR) as will be described later.
The basic headrest unit (HR') is preformed by providing a pair of
headrest stays (D) and (D) in the afore-said trim cover assembly (A) so
as to project outwardly through the respective holes formed in a bottom
wall of the trim cover assembly (A) and also by inserting and attaching a
lower small-diameter end portion of an injection nozzle (C) in a hole
(not shown) formed in substantially a center of the bottom wall of the
trim cover assembly (A). It is noted that the bottom wall of trim cover
assembly (A) is to face downwardly when a resultant headrest is mounted
on a seat, thus constituting a bottom side or bottom wall of the
headrest.

[0034]Referring to FIG. 2, it is seen that the injection nozzle (C) is
formed with a downwardly tapered lower small-diameter portion (C-2) and
an upper large-diameter connecting portion (C-1) which is large in
diameter than that lower portion (C-2). The lower small-diameter portion
(C-2) is shown as extending through and secured in the bottom wall of
trim cover assembly (A), while the upper large-diameter connecting
portion (C-1) is shown as projecting upwardly from the latter.

[0035]The thus-preformed basic headrest unit (HR') is placed in a foaming
die (1) comprising a first die element (10A) and a second die element
(10B), wherein the first and second die elements (10A) and (10B) are
hingedly connected together and may be moved away from each other, so
that the foaming die (1) is set in an opened state as seen in FIG. 6.

[0036]The first die element (10A) has, defined therein, an operative die
cavity (10A-1) and a pair of concave portions (10A-2) and (10A-2)
extending through the die element (1A), wherein each of the concave
portions (10A-2) is so configured to receive one half of the headrest
stay (D). Designation (10C) generally denotes an injection nozzle support
portion integrally formed with the foaming die (1), which is adapted to
receive and support an injection nozzle (C) to be described later.
Designation (10C-1) denotes one half of that injection nozzle support
portion (10C) (hereinafter, "nozzle support half (10C-1)"), which is
defined integrally with the first die element (1A). As shown, formed in
that nozzle support half (10C-1) is a recessed portion (10A-3) which
extends therethrough in such a manner as to communicate the operative die
cavity (10A-1) with the outside of the nozzle support half (10C-1), the
recessed portion (10A-3) being so configured to receive an entire one
half of an injection nozzle (C) therein. Thus, the recessed portion
(10A-3) has an opening defined in the top of the nozzle support half
(10C-1).

[0037]Likewise, the second die element (10B) has, defined therein, an
operative die cavity (10B-1) and a pair of concave portions (10B-2) and
(10B-2) each being so configured to receive the other half of the
headrest stay (D). Designation (10C-2) denotes the other half of the
injection nozzle support portion (10C) (hereinafter, "nozzle support half
(10C-2)"), which is defined integrally with the second die element (10A).
As shown, formed in that nozzle support half (10C-2) is a recessed
portion (10B-3) so configured to receive the entire other half of the
injection nozzle (C) therein. The recessed portion (10B-3) extends
through the nozzle support half (10C-2) in such a manner as to
communicate the operative die cavity (10B-1) with the outside of the
nozzle support half (10C-2), thus having an opening defined in the top of
that particular nozzle support half.

[0038]It is therefore to be seen that, when the first and second die
elements (10A) and (10B) are mated with other to close the foaming die
(1), both two operative die cavities (10A-1) and (10B-1) are also mated
together to define a space for accommodating the entirety of trim cover
assembly (A) therein for a foaming operation purpose to be set forth
later, and at the same time, both two recessed portions (10A-3) and
(10B-3) are mated together to define a through-bore for receiving and
supporting an entirety of the injection nozzle (C) therein, while
defining an opening in the top of a resultant nozzle support portion
(10C).

[0039]Now, a specific description will be made of the device (HD) for
forming headrest in conjunction with the above-described foaming die (1).

[0040]As understandable from FIG. 1, the device (HD) is basically
comprised of: [0041](a) a lid engagement mechanism (2) provided on the
foaming die (1); [0042](b) a support frame (F) fixedly mounted on a floor
(G); [0043](c) an injection molding unit (E) having an injection
mechanism (3), wherein the injection mechanism (3) is supported on an
upper frame member (F1) of the support frame (F) in a vertically movable
manner; [0044](d) a lid disengagement mechanism (4) provided to the
injection molding unit (3) in such a manner as to be movable and
suspendent from the latter; [0045](e) an injection gun cleaning unit (5)
provided on the upper frame member (F1) in a horizontally movable manner;
[0046](f) a turn table (6) on which are securely placed a predetermined
number of foaming die units each including the foaming die (1), as
designated by (1A), (1B) and (1C) for example, the turn table (6) being
rotatably provided on the floor (G) under those injection mechanism (3)
and injection gun cleaning unit (5).

[0047]The lid engagement mechanism (2) is provided on the foaming die (1)
and operable for engaging a lid member (at 21 and 22) in an opening of
the upper connecting portion (C-1) of injection nozzle (C) placed in the
nozzle support portion (10C) and temporarily keeping that injection
nozzle portion (C-1) in a closed or sealed state to prevent leakage of
liquid foaming agent therethrough, as will be elaborated. This lid
engagement mechanism (2) is composed of: a plate member (20) pivotally
connected with a base member (10D); a pair of first and second circular
lid members (21) and (22) which are fixed to the plate member (20); and a
spring (25). The base member (10D) is integrally connected with the
injection nozzle support portion (10C) as well as the first die element
(10A).

[0048]Specifically, as seen FIGS. 2 and 6, the plate member (20) is
pivotally connected at the base end portion thereof by a pin (2A) to the
base member (10D) integrally formed with the first die element (10A),
thereby allowing the free end portion thereof to rotate vertically about
that pin (2A), and the first and second circular lid members (21) and
(22) are fixed on the bottom surface of the free end portion of the plate
member (20). In this regard, the circular first and second lid members
(21) (22) are formed integrally together as shown, thus forming one lid
element workable for engaging and closing the opening of the upper
connecting portion (C-1) of injection nozzle (C) as will be described
later. It is to be seen that the first circular lid member (21), larger
in diameter than the second lid member (22), is adapted for closely
contacting the entire circular distal end of the upper connecting portion
(C-1) of injection nozzle (C), whereas the second circular lid member
(22) is adapted to be engaged and fitted in the circular opening of that
connecting portion (C-1 ).

[0049]The spring (25) is depicted to be connected between the afore-said
base member (10D) and the bottom surface of the base end portion of the
afore-said plate member (20). Under upwardly resilient force of the
spring (25), the free end portion of the plate member (20) is biasingly
caused to rotate downwardly about the pin (2A), so that the first and
second lid members (21) (22) are normally biased to fit engagement in the
opening of the upper large-diameter connecting portion (C-1) of injection
nozzle (C) as will be stated later.

[0050]The turn table (6) is operatively connected at the central shaft
(6A) thereof with a motor and controlled by control elements, though not
shown, with such an arrangement that the turn table (6) is rotated
intermittently in order that one of the foaming die units (at 1A, 1B and
1C for example) is transferred to and stopped at a predetermined position
right below the injection gun (30) associated with the injection molding
unit (E) for foaming operation to be described later.

[0051]The injection molding unit (E) itself is a conventional injection
molding mechanism used for injecting a liquid synthetic resin or liquid
foaming agent through injection gun into a molding or die. In the
illustrative embodiment, the injection molding unit (E) includes: an
injection mechanism (3) supported by the upper frame member (F1) in a
vertically movable manner; and an injection gun (30) provided in the
injection mechanism (3) so as to be movable vertically to and from the
latter in a telescopic manner. Upon operation of the injection molding
unit (E), a liquid foaming agent (see the designation B' in FIG. 3)
stored therein is transferred to the injection mechanism (3) and
discharged from the injection gun (30) to the outside. While not shown,
the injection molding unit (E) includes a mechanism for causing vertical
movement of the injection mechanism (3) and also causing vertical
movement of the injection gun (30), wherein such unshod mechanism is
operatively connected with a motor (M1). Hence, operation of the motor
(M1) causes each of the injection mechanism (3) and injection gun (30) to
move vertically in a direction toward and away from one of the afore-said
foaming die units which is just positioned right below the injection gun
(30).

[0052]The lid engagement mechanism (4) basically comprises: an upper
stationary pressure plate element (4B) fixed to the foregoing injection
mechanism (3); and a lower movable pressure plate element (4A) pivotally
connected with that upper stationary pressure plate portion (4B); and an
engagement piece (23) fixed on the upper surface of base end portion of
the aforementioned plate member (20) associated with the lid
disengagement mechanism (2). It is to be understood that the upper and
lower pressure plate elements (4B) and (4A) constitute one vertically
extending pressure plate element workable for giving a downward pressure
to the plate member (20) of lid closing mechanism (2), thereby causing
that plate member (20) to rotate so as to disengage the lid members (21
and 22) from the opening of upper connecting portion (C-1) of injection
nozzle (C) as will be described later.

[0053]With regard to such lid disengagement mechanism (4), at first, a
horizontal support frame (43) is fixed to the injection mechanism (3) so
as to project outwardly and horizontally therefrom, as shown, and the
above-defined one vertically suspending pressure rod element is fixed to
that horizontal support frame (43). Specifically, the upper stationary
pressure plate element (4B) is fixed to the outwardly projected
horizontal support frame (43), whereas on the other hand, the lower
movable pressure plate element (4A) is provided with a pair of first and
second rollers (41 ) and (42) and pivotally connected with the upper
stationary pressure plate element (4B) by means of a pin. The upper
stationary and lower movable plate elements (40B) and (40A) are formed
with an upper sloped stopper edge (40Be) and a lower sloped stopper edge
(40Ba), respectively, wherein the inclination angle of the former (40Be)
is equal to that of the latter (40Be), such that, when such two stopper
edges (40Ba) (40Be) are contacted with each other, both of the upper
stationary and lower movable pressure plate elements (40B) (40A) extend
in the same vertical direction and in continuous manner as if they formed
one unitary pressure plate element suspendent from and perpendicular with
the horizontal support frame (43), as shown in FIG. 2. Under such
perpendicularly extending state, by the reason of the above-discussed
full contact between the two sloped edges (40Ae) (40Be), the lower
movable pressure plate element (40A) is completely prevented from being
rotated and inclined about the pin relative to the vertically extending
upper stationary pressure plate element (40B). This is only effective
when a vertical force or pressure is directly and coaxially applied from
the upper stationary pressure element (40B) to that lower pressure plate
element (40A). On the other hand, when a generally horizontal or lateral
force is applied to the lower movable pressure element (40A) in a
direction toward the body of the injection mechanism (3), the lower
movable pressure plate element (40A) is rotated and inclined relative to
the upper stationary pressure plate element (40B) in a direction toward
the body of the fore-stated injection mechanism (3), as understandable
from FIG. 5 for instance.

[0054]The injection gun cleaning unit (5) comprises an operative hollow
body (50) and a rotating brush (51) rotatably supported in the operative
hollow body (50). Specifically, the operative hollow body (50) is so
formed to have such sectional configuration as shown in FIG. 5, which
includes an acutely sloped wall region (52), a gently sloped wall region
(53), an upper horizontal planar wall region (54) and an opening (55)
formed in that upper horizontal planar wall region (54). Rotatably
supported in so formed hollow body (50) is the rotating brush (51 ) which
is of substantially columnar shape, such that a localized upper part of
the rotating brush (51) is exposed from the opening (55). While not
shown, the rotating brush (51) is operatively connected with a motor
through appropriate mechanisms and control elements for a cleaning
purpose to be stated later. The operative hollow body (50) is fixedly
mounted on a horizontal arm portion (57) of a support arm (55) is movably
connected with the upper frame member (F1) of the frame (F). The support
arm (55) is moved by operation of a motor (M2) in a horizontal direction
towards and away from the foregoing injection mechanism (3) through
unshod mechanism and control elements, thereby causing translation of the
injection gun cleaning unit (5) under the injection mechanism (3) as
indicated by the horizontal arrow in FIG. 1.

[0055]A description will be made of operation of the above-described
automated headrest production device (HD).

[0056]First of all, as stated previously, the basic headrest unit (HR') is
placed in a cavity (10A-1 and 10B-1) of mutually mated die elements (10A
and 10B), such that the two headrest stays (D) are retained in the
respective two through-holes each being defined by the corresponding
mated two concave portions (10A-2) (10B-2), while the injection nozzle
(C) is retained in a through-bore defined by mated two concave portions
(10A-3) (10B-3). At this point, as seen in FIG. 2, the lid engagement
mechanism (2) is in the state of closing the injection nozzle (C),
because, under the biasing force of the sprint (25), the first lid member
(21) thereof is kept to be in close contact upon the circular upper edge
of the injection nozzle upper connecting portion (C-1), while the second
lid member (22) there of is kept to be inserted in the inner opening of
that particular injection nozzle upper connecting portion (C-1). In other
words, as the plate member (20) is biasingly caused by the spring (25) to
rotate downwardly toward the top of the nozzle support portion (10C), the
opening of the injection nozzle upper connecting portion (C-1 ) is kept
closed by the first and second lid members (21) (22). In that way, one
foaming die unit (hereinafter, designated by 1(A) for example) with the
thus-closed foaming die (1) is provided, by attaching thereto unshown
required frame for releasable connection with the turn table (6)

[0057]Then, such foaming die unit (1A) is securely mounted on a
predetermined position of the turn table (6).

[0058]When the foaming die unit (1A) is transferred and stopped by the
turn table (6) at an injection section where the injection mechanism (3)
is disposed, the injection nozzle support portion (10C) of foaming die
unit (1A) is positioned right below the injection gun (30), and the motor
(M1) is automatically operated to cause downward movement of the
injection mechanism (3) toward the foaming die unit (1A), with concurrent
downward movement of both upper stationary and lower movable pressure
plate elements (40B) (40A) of lid disengagement mechanism (4) toward the
engagement piece (23) fixed on the plate member (20) of lid engagement
mechanism (2), as indicated by the arrow in FIG. 2. Then, as readily
understandable from FIG. 3, the first roller (41) of the lower movable
pressure plate element (40A) are first contacted with and received in the
recessed area (23A) of the engagement piece (23), and with further
downward movement of both of those two pressure plate elements (40B)
(40A), the plate member (20) of lid engagement mechanism (2) is rotated
anticlockwise or upwardly about the pin (2A) against the biasing force of
the spring (25). At this point, it is to be noted that (i) the lower
sloped stopper edge (40Ae) of the upper stationary pressure plate element
(40A) is in contact with the upper sloped stopper edge (40Be) of the
lower movable pressure plate element (40B), thereby retaining the lower
movable pressure plate element (40B) in its vertically extending state
coaxially continuous with the upper stationary pressure plate element
(40B) and thus prevented against rotation relative to the latter, (ii)
such vertically extending state of both those two plate elements (40A)
(40B) is maintained because of only downward straight force being applied
thereto from the engagement piece (23) of the plate member (20), and (ii)
the first roller (41) of the lower movable pressure plate element (40B),
engaged in the recessed portion (23A) of that engagement piece (23), is
actually rotated to thereby prevent application of lateral force to that
particular pressure plate element (40B). This arrangement insures that
the lower movable pressure plate element (40B) is maintained in
vertically extending state, without being rotated or inclined relative to
the upper stationary pressure plate element (40A), and the plate member
(20) is smoothly rotated anticlockwise about the pin (2A) by both two
pressure plate elements (40A) (40B) being moved downwardly with the
concurrent downward movement of the injection mechanism (3).

[0059]As a result thereof, the first and second lid members (21) (22) are
disengaged from the upper connecting portion (C-1) of injection nozzle
(C), and the injection mechanism (3) is stopped at a predetermined
position, at which time, the plate member (2) as well as those two lid
members (21) (22) are temporarily retained at an inoperative position, as
shown in FIG. 3, which does not interfere with the injection gun (30).

[0060]Then, the injection gun (30), which contains a liquid foaming agent
(B') therein, is automatically moved downwardly from the body of
injection mechanism (3) toward the injection nozzle support portion
(10C). so that the distal end portion (30A) thereof is fit engaged in the
upper connecting portion (C-1) of injection nozzle (C) retained in that
injection nozzle support portion (10C). Responsive thereto, the injection
molding unit (E) is operated to discharge the liquid foaming agent (B')
from the injection gun (30), so that a predetermined volume of the liquid
foaming agent (B') is injected through the injection nozzle (C) into the
trim cover assembly (A) placed in the forming die (1), as shown in FIG.
3.

[0061]Thereafter, referring to FIG. 4, as indicated by the arrow {circle
around (1)}, the injection gun (30) is first moved upwardly, disengaged
from the upper connecting portion (C-1) of injection nozzle (1) and
withdrawn into the body of the injection mechanism (3), whereupon that
upper connecting portion (C-1) of injection nozzle (1) is opened. Shortly
thereafter, the injection mechanism (3) is moved upwardly as indicated by
the arrow {circle around (4)}. With such sequential upward movement of
the injection gun (30) and injection mechanism (3), both two pressure
plate elements (40A) and (40B) are simultaneously raised, which in turn
allows the plate member (20) to simultaneously rotate clockwise about the
pin (2A) under the biasing force of the spring (25), whereby the first
and second lid members (21) and (22) are automatically displaced
downwardly towards the opened upper connecting portion (C-1) of injection
nozzle (1), without interference with the injection gun (30). As a result
thereof, it is seen from FIG. 4 that the injection nozzle upper
connecting portion (C-1) is completely closed and further retained in a
sealed state against leakage of the liquid foaming agent (B')
therethrough, because, under the biasing force of spring (25), the first
lid member (21) is retained in a close contact upon the entire peripheral
edge of the injection nozzle upper connecting portion (C-1), while at the
AMET time, the second lid member (22) is retained in a close contact with
the circumferential inner surface of that particular portion (C-1).

[0062]Under such sealed state, the liquid foaming agent (B') is cured into
an increased mass of a foaming padding (B) filled in the trim cover
assembly (A) as seen in FIG. 4, without being leaked outwardly through
the injection nozzle (C). It is also to be appreciated that, during the
foaming operation, the injection nozzle (C) is maintained in closed state
by the biasing force of the spring (25) to insure such prevention of
leakage of liquid foaming agent, thereby eliminating the necessity for a
worker to manually keep on closing the injection nozzle (C) during the
foaming operation.

[0063]After the completion of the foregoing foaming operations, it is to
be noted that, as seen in FIG. 5, a residual portion of the liquid
foaming agent (B') within the injection gun (30) remains protrudent from
the distal end (30E) of that injection gun (30), and it is necessary to
clean off such residual protrudent portion of liquid foaming agent (B').

[0064]In accordance with the present invention, at this stage, the turn
table (6) is rotated to displace the foaming die unit (1A) away from the
current position where the injection mechanism (3) exists, after which,
the motor (M2) is operated to cause translation of the support frame
member (56) along the guide member (54) towards the injection mechanism
(3), so that the injection gun cleaning unit (5) or the operative body
(52) of the injection gun cleaning unit (5) is moved to a vertically
extending pair of the upper stationary and lower movable pressure plate
elements (40A) (40B).

[0065]Reference is now made to FIG. 6. With further movement of the
operative hollow body (50) of injection cleaning unit (5) as indicated by
the arrow, it is to be seen from the one-dot chain lines in the FIG. 6
that the first roller (41 ) of the lower movable pressure plate element
(40A) is contacted with and rotates on and along the acutely sloped wall
region (53) of the operative body (50), which causes simultaneous
anticlockwise rotation of the lower movable pressure plate element (40A)
relative to the upper stationary pressure plate element (40B). Also, with
yet further movement of the operative hollow body (50), it is to be seen
from the one-dot chain lines and solid liens in the FIG. 6 that the first
roller (41) rolls on and along the gently sloped wall region (52) of
operative body (5), rides over both opening (55) and the exposed part of
the cleaning brush (51), and finally rides on and along the upper planar
wall region (54) of the operative body (5). In that way, the operative
hollow body (50) is smoothly moved, without being intercepted by the
pressure plate element (40A), to a predetermined point where the cleaning
brush (51) is located right below the injection gun (30).

[0066]When the operative hollow body (50) reaches that predetermined
point, with the cleaning brush (51) being located right below the
injection gun (30), the motor (M2) is operated to cause downward movement
of the injection gun (30) towards the exposed part of the cleaning brush
(51). Upon the protrudent residual portion of the liquid foaming agent
(B') as well as the injection gun lower edge (30E) being contacted upon
the exposed part of cleaning brush (51), the injection gun (30) is
stopped and the cleaning brush (51) is rotated to clean off that residual
portion of liquid foaming agent (B') attached to the lower edge (30E) of
injection gun (30) and discharge the same into the inside of the
operative hollow body (5).

[0067]After the residual portion of liquid foaming agent (B') having
cleaned off from the lower edge (30E) of injection gun (30), the motor
(M1) is operated reversely to cause the injection gun (30) to move
upwardly from the cleaning brush (51 ), after which, the motor (M2) is
operated reversely to cause the operative hollow body (5) to move away
from the injection gun (30) and return the same to the home position. At
this point, of course, the inclined lower movable pressure plate element
(40A) is rotated back to the normal vertically extending position where
it extends vertically in alignment with the upper stationary pressure
plate element (40B) as shown in FIG. 2, with the roller (41 ) running in
reverse direction on and along the outer contour portions (at 54, 55, 52
and 53) of the operative body (50).

[0068]Finally, the foaming die unit (1A) is taken out from the turn table
(6), and the first and second foaming die elements (10A) (10B) of the
foaming die (1) are opened, so that a resultant headrest (HR) is taken
out therefrom. FIG. 7 shows the resultant headrest (HR) produced by the
device (DH).

[0069]Likewise as described above, each of another foaming die units (at 1
(B) for example) will undergo the same steps of operations effected so
far by the device (DH) to produce a plurality of resultant headrests (HR)
in an automated manner.

[0070]While having described the present invention thus far, it should be
understood that the invention is not limited to the illustrated
embodiment, but any other modification, replacement and addition may be
applied thereto, without departing from the scopes of the appended
claims. For example, the present invention may be used for forming
armrests.